Insole product and method of making same

Abstract

A film encapsulated, pressurized gas cushion insole product which maintains its shape by means of a core fabric therein to which a desiccant may be added, if desired. To contain the gas for long periods of time, the film contains a layer of polyvinylalcohol.

I claim: 
     
       1. An insole product comprising: a core fabric, a barrier film encapsulating said core fabric and a low molecular weight gas confined within said barrier film, said barrier film comprising a polyvinylalcohol film layer, a nylon 6 layer on both sides thereof, a tie-layer of adhesive on at least one side of said nylon 6 layers and a low density polyethylene layer adhered to said tie-layer of adhesive adjacent said core fabric. 
     
     
       2. The product of claim 1 wherein a second tie-coat adhesive layer is on the outer side of the other nylon 6 layer, a second layer of low density polyethylene adhered to said second tie-layer of adhesive and a cover fabric bonded to said second low density polyethylene layer. 
     
     
       3. The product of claim 2 wherein said core fabric is a double plush warp knit fabric. 
     
     
       4. An insole product comprising: a core fabric, a desiccant on at least one surface of said core fabric, a barrier film encapsulating said core fabric and a low molecular weight gas confined within said barrier film, said barrier film comprising a polyvinylalcohol film layer, a nylon 6 layer on both sides thereof, a tie-layer of adhesive on at least one side of said nylon 6 layers and a low density polyethylene layer adhered to said tie-layer of adhesive adjacent said core fabric. 
     
     
       5. The product of claim 4 wherein a second tie-layer of adhesive is on the outer side of the other nylon 6 layer, a second layer of low density polyethylene adhered to said second tie-layer of adhesive and a cover fabric bonded to said second low density polyethylene layer. 
     
     
       6. The product of claim 5 wherein said core fabric is a double plush warp knit fabric. 
     
     
       7. An insole product comprising: a core fabric, a barrier film encapsulating said core fabric and a gas confined within said barrier film, said barrier film comprises a polyvinylalcohol film layer, a nylon 6 layer on both sides thereof, a tie-layer of adhesive on at least one side of said nylon 6 layers and a low density polyethylene layer adhered to said tie-layer of adhesive adjacent said core fabric. 
     
     
       8. The product of claim 7 wherein a second tie-coat adhesive layer is on the outer side of the other nylon 6 layer, a second layer of low density polyethylene adhered to said second tie-layer of adhesive and a cover fabric bonded to said second low density polyethylene layer. 
     
     
       9. The product of claim 8 wherein said core fabric is a double plush warp knit fabric. 
     
     
       10. The product of claim 9 wherein a desiccant is on at least one surface of said core fabric. 
     
     
       11. The product of claim 10 wherein said desiccant is lithium chloride brine. 
     
     
       12. An insole product comprising: a core fabric, a first barrier film on top of said core fabric, a second barrier film on the bottom of said core fabric sealed to said first barrier film encapsulating said core fabric, a dessicant located on one surface of said core fabric and a low molecular weight pressurized gas confined between said first and second barrier films at a pressure in the range of 10-20 p.s.i.g. 
     
     
       13. The insole product of claim 12 wherein said desiccant is lithium bromide brine. 
     
     
       14. The product of claim 13 wherein said pressure is about 27 p.s.i.g.